Process for making gamma-branched alcohol

ABSTRACT

This disclosure relates to a process for making an alcohol product comprising a gamma-branched alcohol from a vinylidene olefin by hydroformylation.

PRIORITY

This application claims priority to and the benefit of U.S. ProvisionalApplication No. 62/551,005, filed Aug. 28, 2017, and is incorporatedherein by reference.

This disclosure relates to alcohols and processes for making the same.In particular, this disclosure relates to gamma-branched alcohols andprocesses for making the same.

BACKGROUND OF THE DISCLOSURE

Branched aliphatic primary alcohols, especially those having long carbonchains, have found use in many applications such as surfactants,solvents, wetting agents, solubilizing agents, emulsifiers, or as anintermediates for making derivatives such as esters and ethers that canbe used as surfactants, solvents, wetting agents, solubilizing agents,emulsifiers, and lubricant base stocks or additives.

A specific type of branched aliphatic alcohols are Guerbet alcohols,which are beta-branched primary alcohols having the following generalstructure:

where R¹ and R² can be any hydrocarbyl group, preferably alkyl groupssuch as linear alkyl groups. Guerbet alcohols and derivatives thereof,such as esters thereof, have found use as lubricant base stocks. Guerbetalcohols can be produced by Guerbet reaction, in which two primaryalcohol molecules condense to produce a beta-branched primary alcoholmolecule and water.

Recently, industrial interests in gamma-branched alcohols havingstructures similar to Guerbet alcohols as follows have grown:

where R¹ and R² can be any hydrocarbyl group. Such gamma-branchedalcohols cannot be produced via two molecules of primary alcohols.

U.S. Pat. No. 8,383,869 B2 discloses a process for making suchgamma-branched alcohols from a terminal olefin including a first step ofproducing a vinylidene olefin dimer of the terminal olefin, followed byhydroformylation of the vinylidene olefin dimer. However, this patentteaches that in the hydroformylation process, multiple alcohol isomerswill be produced. Because the isomers have the same molecular weight andsimilar molecular structure, it would be very difficult to produce onegamma-branched alcohol at high purity. JP2005-298443A discloses asimilar process for making gamma-branched alcohols from alpha-olefin.While a high purity gamma-branched alcohol was reportedly produced in anexample in this patent publication, the purity still has room forimprovement. In addition, the overall yield of the gamma-branchedalcohol product from the terminal olefin as disclosed in JP2005-298443Ahas room for improvement as well.

A high-purity gamma-alcohol product can be far more useful than amixture of multiple alcohols having different molecular structures. Thisis especially true where the gamma-branched alcohol is used as a feed toproduce a derivative thereof, and a high purity of the derivative isdesired for its end application.

Thus, there is a need for a high purity gamma-branched alcohol productsand a process for making high-purity gamma-branched alcohol productswith a high yield.

This disclosure satisfy this and other needs.

SUMMARY OF THE DISCLOSURE

It has been found that, surprisingly and contrary to the teachings inU.S. Pat. No. 8,383,869, by using a Rh-containing carbonylation catalystin combination with a phosphine compound, followed by hydrogenation, onecan effect the hydroformylation of a vinylidene olefin with an overallselectivity toward gamma-branched alcohol at much higher level thanreported in the prior art.

This disclosure relates to a process for making an alcohol productcomprising a gamma-branched alcohol having a formula (F-I) below:

where each R¹ group, the same or different, is independently a C2-C28linear or branched alkyl group, the process comprising the followingsteps: (I) providing a vinylidene feed comprising a vinylidene olefinhaving a formula (F-II) below:

where the R¹ groups correspond to the R¹ groups in formula (F-I) above;(II) contacting the vinylidene olefin with carbon monoxide and hydrogenin the presence of a carbonylation catalyst system comprising arhodium-containing compound and a phosphine compound to obtain acarbonylation product mixture; and (III) contacting the carbonylationproduct mixture with hydrogen in the presence of a hydrogenationcatalyst to produce an alcohol product comprising the gamma-branchedalcohol, wherein: steps (II) and (III) combined have a selectivity ofthe vinylidene olefin toward the gamma-branched alcohol of at least 90%.

Further objects, features and advantages of this disclosure will beunderstood by reference to the following drawings and detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a 13C-NMR spectra of the C21-alcohol made in Example B1 inthis disclosure.

FIG. 2 is a super-imposed diagram showing and comparing portions of thegas chromatography spectra of the C21-alcohol made in Example B1 andthat of the alcohol product made in Example B2.

FIG. 3 is a super-imposed diagram showing and comparing portions of the13C-NMR spectra of the C21-alcohol made in Example B1 and that of thealcohol product made in Example B2.

DETAILED DESCRIPTION OF THE DISCLOSURE

Definitions

In this disclosure, the indefinite article “a” or “an” means at leastone, unless it is clearly specified or indicated by the context to meanone.

The term “alkyl group” or “alkyl” interchangeably refers to a saturatedhydrocarbyl group consisting of carbon and hydrogen atoms. “Linear alkylgroup” refers to a non-cyclic alkyl group in which all carbon atoms arecovalently connected to no more than two carbon atoms. “Branched alkylgroup” refers to a non-cyclic alkyl group in which at least one carbonatom is covalently connected to more than two carbon atoms. “Cycloalkylgroup” refers to an alkyl group in which all carbon atoms form a ringstructure comprising one or more rings.

The term “aryl group” refers to an unsaturated, cyclic hydrocarbyl groupconsisting of carbon and hydrogen atoms in which the carbon atoms jointo form a conjugated π system. Non-limiting examples of aryl groupsinclude phenyl, 1-naphthyl, 2-naphthyl, 3-naphthyl, and the like.

The term “arylalkyl group” refers to an alkyl group substituted by anaryl group or alkylaryl group. None-limiting examples of arylalkyl groupinclude benzyl, 2-phenylpropyl, 4-phenylbutyl, 3-(3-methylphenyl)propyl,3-(p-tolyl)propyl, and the like.

The term “alkylaryl group” refers to an aryl group substituted by analkyl group. Non-limiting examples of alkylaryl group include2-methylphenyl, 3-methylphenyl, 4-methylphenyl, 2-methyl-1-naphtyl,6-phenylhexyl, 5-pentylphenyl, 4-butylphenyl, 4-terterybutylphenyl,7-phenylheptanyl, 4-octylphenyl, and the like.

The term “cycloalkylalkyl group” refers to an alkyl group substituted bya cycloalkyl group or an alkylcycloalkyl group. An example ofcycloalkylalkyl group is cyclohexylmethyl.

The term “alkylcycloalkyl group” refers to a cycloalkyl groupsubstituted by an alkyl group. Non-limiting examples of alkylcycloalkylgroup include 2-methylcyclohexyl, 3-methylcyclohexyl,4-methylcyclohexyl, 4-tertiary butyl cyclohexyl, 4-phenylcyclohexyl,cyclohexylpentyl, and the like.

The term “Hydrocarbyl group” or “hydrocarbyl” interchangeably refers toa group consisting of hydrogen and carbon atoms only. A hydrocarbylgroup can be saturated or unsaturated, linear or branched, cyclic oracyclic, containing a cyclic structure or free of cyclic structure, andaromatic or non-aromatic.

“Cn” group or compound refers to a group or a compound comprising carbonatoms at total number thereof of n. Thus, “Cm-Cn” or “Cm to Cn” group orcompound refers to a group or compound comprising carbon atoms at atotal number thereof in the range from m to n. Thus, a C1-C50 alkylgroup refers to an alkyl group comprising carbon atoms at a total numberthereof in the range from 1 to 50.

The term “carbon backbone” in an alkane or an alkyl group refers to thelongest straight carbon chain in the molecule of the compound or thegroup in question.

The term “carbon backbone” of an olefin is defined as the straightcarbon chain therein including a C═C functionality having the largestnumber of carbon atoms.

The term “olefin” refers to an unsaturated hydrocarbon compound having ahydrocarbon chain containing at least one carbon-to-carbon double bondin the structure thereof, wherein the carbon-to-carbon double bond doesnot constitute a part of an aromatic ring. The olefin may be linear,branched linear, or cyclic.

The term “terminal olefin” refers to an olefin having a terminalcarbon-to-carbon double bond in the structure thereof ((R¹R²)—C═CH₂,where R¹ and R² can be independently hydrogen or any hydrocarbyl group,preferably R¹ is hydrogen, and R² is an alkyl group). A “linear terminalolefin” is a terminal olefin defined in this paragraph wherein R¹ ishydrogen, and R² is hydrogen or a linear alkyl group.

The term “vinyl” means an olefin having the following formula:

wherein R is a hydrocarbyl group, preferably a saturated hydrocarbylgroup such as an alkyl group.

The term “vinylidene” means an olefin having the following formula:

wherein R¹ and R² are each independently a hydrocarbyl group, preferablya saturated hydrocarbyl group such as alkyl group.

The term “1,2-di-substituted vinylene” means

-   (i) an olefin having the following formula:

or

-   (ii) an olefin having the following formula:

or

-   (iii) a mixture of (i) and (ii) at any proportion thereof,    wherein R¹ and R², the same or different at each occurrence, are    each independently a hydrocarbyl group, preferably saturated    hydrocarbyl group such as alkyl group.

The term “tri-substituted vinylene” means an olefin having the followingformula:

wherein R¹, R², and R³ are each independently a hydrocarbyl group,preferably a saturated hydrocarbyl group such as alkyl group.

The term “polyalpha-olefin(s)” (“PAO(s)”) includes any oligomer(s) andpolymer(s) of one or more terminal olefin monomer(s). PAOs areoligomeric or polymeric molecules produced from the polymerizationreactions of terminal olefin monomer molecules in the presence of acatalyst system, optionally further hydrogenated to remove residualcarbon-carbon double bonds therein. Thus, the PAO can be a dimer(resulting from two terminal olefin molecules), a trimer (resulting fromthree terminal olefin molecules), a tetramer (resulting from fourterminal olefin molecules), or any other oligomer or polymer comprisingtwo or more structure units derived from one or more terminal olefinmonomer(s). The PAO molecule can be highly regio-regular, such that thebulk material exhibits an isotacticity, or a syndiotacticity whenmeasured by ¹³C NMR. The PAO molecule can be highly regio-irregular,such that the bulk material is substantially atactic when measured by¹³C NMR. A PAO material made by using a metallocene-based catalystsystem is typically called a metallocene-PAO (“mPAO”), and a PAOmaterial made by using traditional non-metallocene-based catalysts(e.g., Lewis acids, supported chromium oxide, and the like) is typicallycalled a conventional PAO (“cPAO”). A PAO material that has not beenhydrogenated and therefore is unsaturated is called an unhydrogenatedPAO (“uPAO”).

The term “rhodium carbonyl compounds” means compounds comprising rhodiumcovalently bonded to at least one carbonyl group. Non-limiting examplesof rhodium carbonyl compounds include: Rh₄(CO)₁₂, Rh₆(CO)₁₆,(acetylacetonato)dicarbonylrhodium(I), chlorodicarbonylrhodium dimer,and chlorobis(ethylene)rhodium dimer.

The term “phosphine compound” refers to a phosphorous-containing organiccompound having the formula PR₃, where R is a hydrocarbyl group,preferably an aryl group, an alkylaryl group, an alkyl group, or anarylalkyl group.

The term “syngas” means a mixture of carbon monoxide and hydrogen,preferably at a molar ratio of 1:1.

The term “selectivity” of a terminal olefin in a reaction toward a givenproduct species means the percentage of the terminal olefin convertedinto the given product species on the basis of the all of the terminalolefin converted. Thus, if in a specific oligomerization reaction, 5% ofthe terminal olefin monomer is converted into trimer, then theselectivity of the terminal olefin toward trimer in the oligomerizationreaction is 5%.

In this disclosure, all molecular weight data are in the unit of gramsper mole (g·mol⁻¹).

NMR spectroscopy provides key structural information about thesynthesized polymers. Proton NMR (¹H-NMR) analysis of the unsaturatedPAO product gives a quantitative breakdown of the olefinic structuretypes (viz. vinyl, 1,2-di-substituted, tri-substituted, and vinylidene).In this disclosure, compositions of mixtures of olefins comprisingterminal olefins (vinyls and vinylidenes) and internal olefins(1,2-di-substituted vinylenes and tri-substituted vinylenes) aredetermined by using ¹H-NMR. Specifically, a NMR instrument of at least a500 MHz is run under the following conditions: a 30° flip angle RFpulse, 120 scans, with a delay of 5 seconds between pulses; sampledissolved in CDCl₃ (deuterated chloroform); and signal collectiontemperature at 25° C. The following approach is taken in determining theconcentrations of the various olefins among all of the olefins from anNMR spectrum. First, peaks corresponding to different types of hydrogenatoms in vinyls (T1), vinylidenes (T2), 1,2-di-substituted vinylenes(T3), and tri-substituted vinylenes (T4) are identified at the peakregions in TABLE I below. Second, areas of each of the above peaks (A1,A2, A3, and A4, respectively) are then integrated. Third, quantities ofeach type of olefins (Q1, Q2, Q3, and Q4, respectively) in moles arecalculated (as A1/2, A2/2, A3/2, and A4, respectively). Fourth, thetotal quantity of all olefins (Qt) in moles is calculated as the sumtotal of all four types (Qt=Q1+Q2+Q3+Q4). Finally, the molarconcentrations (C1, C2, C3, and C4, respectively, in mol %) of each typeof olefin, on the basis of the total molar quantity of all of theolefins, is then calculated (in each case, Ci=100*Qi/Qt).

TABLE I Hydrogen Atoms Peak Number of Quantity Concentration Type OlefinRegion Peak Hydrogen of Olefin of Olefin No. Structure (ppm) Area Atoms(mol) (mol %) T1 CH₂═CH—R¹ 4.95-5.10 A1 2 Q1 = A1/2 C1 T2 CH₂═CR¹R²4.70-4.84 A2 2 Q2 = A2/2 C2 T3 CHR¹═CHR² 5.31-5.55 A3 2 Q3 = A3/2 C3 T4CR¹R² = CH R³ 5.11-5.30 A4 1 Q4 = A4 C4

All percentages in describing chemical compositions herein are by weightunless specified otherwise. “Wt %” means percent by weight.

“Consisting essentially of” means comprising at a concentration byweight of at least 90 wt %, based on the total weight of the mixture inquestion. Thus, an oligomerization product mixture consistingessentially of a dimer comprises dimer at a concentration by weight ofat least 90 wt %, based on the total weight of the oligomerizationproduct mixture.

All numerical values within the detailed description and the claimsherein are modified by “about” or “approximately” the indicated value,taking into account experimental error and variations that would beexpected by a person having ordinary skill in the art.

All kinematic viscosity values in this disclosure are as determinedpursuant to ASTM D445. Kinematic viscosity at 100° C. is reported hereinas KV100, and kinematic viscosity at 40° C. is reported herein as KV40.Unit of all KV100 and KV40 values herein is cSt unless otherwisespecified.

All viscosity index (“VI”) values in this disclosure are as determinedpursuant to ASTM D2270.

I. The Vinylidene Olefin Feed and Processes for Making the Same

I.1 General

The vinylidene olefin useful in the process of this disclosure formaking the gamma-branched alcohol has a formula (F-II) below:

where each R¹, the same or different, can be independently anyhydrocarbyl group, preferably an alkyl group, more preferably a linearor branched alkyl group, still more preferably a linear alkyl group.Preferably each R¹, the same or different, comprises c1 to c2 carbonatoms, where c1 and c2 can be, independently, any integer between 1 and60, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24,26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 68, or70, as long as c1<c2. More preferably c1=2 and c2=40. Still morepreferably c1=4, and c2=30. Preferably each R¹, the same or different,comprises even number of carbon atoms. Particularly desirable examplesof each R¹, the same or different, include: ethyl, n-propyl, n-butyl,n-hexyl, n-octyl, n-decyl, n-dodecyl, n-tetradecyl, n-hexadecyl,n-octadecyl, n-icosyl, n-docosyl, n-tetracosyl, n-hexacosyl, andn-octacosyl. Most preferred R¹ are: n-butyl, n-hexyl, n-octyl, n-decyl,and n-dodecyl, n-tetradecyl, n-hexadecyl, and n-octadecyl.

Each R¹, the same or different, can be a branched alkyl group,preferably a branched alkyl group having the following formula (F-IV):

where R² and R³ are independently hydrocarbyl groups, preferably alkylgroups, more preferably linear or branched alkyl groups, still morepreferably linear alkyl groups, m is an integer and m≥3, preferably m≥4,still more preferably m≥5, still more preferably m≥6, still morepreferably m≥7. Preferably R² and R³ comprises c3 to c4 carbon atoms,where c3 and c4 can be, independently, any integer between 1 and 50,such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26,28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, or 50, as long as c3<c4.More preferably c3=2 and c4=40. Still more preferably c3=4, and c4=30.

Preferably in the formula (F-II) of the vinylidene olefin, the two R¹are identical. Thus, examples of preferred vinylidene olefin having aformula (F-II) useful in the process of this disclosure are:3-methyleneheptane; 4-methylenenonane; 5-methyleneundecane;7-methyleneheptadecane; 9-methylenenonadecane; 11-methylenetricosane;13-methyleneheptacosane; and 15-methylenehentriacontane, and mixturesthereof.

Where the two R¹ groups in formula (F-II) differ, it is highly desirablethat they differ in terms of molar mass thereof by no greater than 145(or 130, 115, 100, 85, 70, 55, 45, 30, or even 15) grams per mole.Preferably in such cases the two R¹ groups differ in terms of totalnumber of carbon atoms contained therein by no greater than 10 (or 9, 8,7, 6, 5, 4, 3, 2, or even 1).

The vinylidene olefin having formula (F-II) can be advantageously madeby dimerization of a monomer feed comprising a terminal olefin having aformula (F-III) below: R¹—CH═CH₂ (F-III). It is highly desirable thatthe monomer feed consists essentially of a single terminal olefin havinga formula (F-III). In such case a single vinylidene olefin having aformula (F-II) where the two R¹ are identical can be advantageously madein the dimerization process, which can be used as the vinylidene olefinfeed in step (I) of the process of this disclosure for makinggamma-branched alcohol product. It is contemplated that the monomer feedmay comprise multiple terminal olefins having differing formulas(F-III). In such case, as discussed below, multiple vinylidene olefinshaving different formulas (F-II) may be produced in the dimerizationreaction, which can be used together as the vinylidene olefin feed formaking a gamma-branched alcohol product comprising multiplegamma-branched alcohol compounds. Where the monomer feed comprisesmultiple terminal olefins, it is highly desirable that they differ interms of molecular weight thereof by no greater than 145 (or 130, 115,100, 85, 70, 55, 45, 30, or even 15) grams per mole. Preferably in suchcases the multiple terminal olefins contained in the monomer feed differin terms of total number of carbon atoms contained therein by no greaterthan 10 (or 9, 8, 7, 6, 5, 4, 3, 2, or even 1).

Such dimerization can be carried out advantageously in the presence of acatalyst system comprising a metallocene compound. U.S. Pat. No.4,658,078 discloses a process for making a vinylidene olefin dimer froma terminal olefin monomer, the content of which is incorporated hereinby reference in its entirety. The batch processes as disclosed in U.S.Pat. No. 4,658,078 resulted in the production of trimers and higheroligomers at various levels along with the intended dimer, which can beremoved by, e.g., distillation, to obtain a substantially pure dimerproduct. The dimer product made in the batch processes of U.S. Pat. No.4,658,078 may contain 1,2-di-substituted vinylene(s) and tri-substitutedvinylenes at various levels. To the extent the concentrations of the1,2-di-substituted vinylene(s) and tri-substituted vinylenes areacceptable to the intended application of this disclosure, the batchprocesses as disclosed in U.S. Pat. No. 4,658,078 may be used to producethe dimer having formula (F-II) above useful in the process for makingthe gamma-branched alcohol in tis disclosure.

Such dimerization can also be carried out in the presence oftrialkylaluminium such as tri(tert-butyl)aluminum as disclosed in U.S.Pat. No. 4,987,788, the content of which is incorporated by reference inits entirety.

Desirably the vinylidene olefin having formula (F-II) feed used in theprocess of this disclosure for making gamma-branched alcohol comprises asingle vinylidene olefin having formula (F-II) having a purity thereofof at least 90 wt %, preferably at least 92 wt %, more preferably atleast 94 wt %, still preferably at least 95 wt %, still more preferably96 wt %, still more preferably at least 97 wt %, still more preferablyat least 98 wt %, still more preferably at least 99 wt %, based on thetotal weight of the olefins contained in the feed.

It is possible to use a mixture of two or more vinylidene olefins havingdifferent formulae (F-II) as the vinylidene olefin feed in the processfor making a mixture of gamma-branched alcohols as the gamma-branchedalcohol product. Desirably, the individual vinylidene olefins containedin the mixture have similar molecular weights, i.e., having molecularweights that differ by no more than, e.g., 145, 130, 115, 100, 85, 70,55, 45, 30, or even 15 grams per mole. Desirably, the individualvinylidene olefins contained in the mixture differ in terms of totalnumber of carbon atoms contained therein by no more than 10, 9, 8, 7, 6,5, 4, 3, 2, or even 1. The individual vinylidene olefins contained inthe mixture can be structural isomers. The vinylidene olefins havingdifferent chemical formulas and/or molecular weight can be convertedinto gamma-branched alcohol compounds having different chemical formulasand/or molecular weight under the same reaction conditions following thesame reaction mechanism. As long as the mixture of gamma-branchedalcohols can be used for the intended application, the correspondingmixture of vinylidene olefin can be used as the vinylidene olefin feedfor making the gamma-branched alcohol product by using the process ofthis disclosure.

It is highly desirable that the vinylidene having formula (F-II) feedused in the process of this disclosure for making gamma-branched alcoholcomprises 1,2-di-substituted vinylene(s) and tri-substituted vinylene(s)as impurities at a total concentration no greater than 5 wt %,preferably no greater than 4 wt %, still more preferably no greater than3 wt %, still more preferably no greater than 2 wt %, still no greaterthan 1 wt %, based on the total weight of olefins contained in the feed.

I.2 Continuous Process for Making High-Purity Vinylidene Olefin Using aCatalyst System Comprising a Metallocene Compound

However, a particularly desirable process for a vinylidene olefin dimerproduct from a terminal olefin feed for use in the process of thisdisclosure is continuous, as opposed to a batch process such as thosedisclosed in U.S. Pat. No. 4,658,078. The oligomerization (dimerizationbeing one) reaction can therefore be carried out in a continuouslyoperated reactor, such as a continuously stirred tank reactor, a plugflow reactor or a loop reactor. Quite surprisingly, it was found that ina continuous process, one can achieve an extremely high selectivitytoward dimer of the terminal olefin monomer and avoid the production ofhigh quantity of trimer and higher oligomer.

This continuous process represents a significant improvement to theprocesses disclosed in U.S. Pat. No. 4,658,078, as it results in theproduction of a high-purity vinylidene olefin dimer of the terminalolefin dimer. The oligomerization reaction pursuant to the continuousprocess features an exceedingly high selectivity toward dimer andexceedingly low selectivity toward trimers and higher oligomers and anexceedingly high selectivity toward vinylidene olefin dimer as opposedto 1,2-di-substituted vinylene and tri-substituted vinylene. Thus, theoligomer mixture obtained from the oligomerization step, upon removal ofresidual terminal olefin monomer and catalyst, can be used directly as ahigh-purity vinylidene olefin dimer for the process of making agamma-branched alcohol of this disclosure. In addition, theoligomerization reaction can be carried out with a high conversion ofthe terminal olefin monomer. Moreover, the oligomerization reaction ofthe continuous process results in little isomerization of the terminalolefin monomer, the dimer, and other oligomers. Therefore, the residualterminal olefin monomer contained in the oligomerization reactionmixture can be separated and recycled to the oligomerization reaction.Last but not least, the oligomerization reaction in the continuousprocess is carried out under mild, steady conditions in a continuousfashion, resulting in a vinylidene olefin dimer intermediate withconsistent composition and quality, which, in turn, can be used formaking a gamma-alcohol product with high purity.

I.2a The Terminal Olefin

The terminal olefin monomer useful in the continuous process for makingthe vinylidene olefin having formula (F-II) can desirably comprise fromn1 to n2 carbon atoms per molecule, where n1 and n2 can be,independently, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28,30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, as longas n1<n2. Preferably n1=4 and n2=50; more preferably n1=6 and n2=40;still more preferably n1=6 and n2=30; still more preferably n1=6 andn2=20.

Preferred terminal olefin monomers are mono-olefins containing one C═Cbond per monomer molecule, though those olefins containing two or moreC═C bonds per monomer molecule can be used as well.

The terminal olefin monomer useful in the continuous process for makingthe vinylidene olefin having formula (F-II) can be preferably a linearterminal olefin. Particularly useful examples of linear terminal olefinsas the monomer for the process of this disclosure are: 1-butene,1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene,1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene,1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-icosene,1-henicosene, 1-docosene, 1-tricosene, 1-tetracosene, 1-pentacosene,1-hexacosene, 1-heptacosene, 1-octacosene, 1-nonacosene, and1-triacontene. Preferred examples of linear terminal olefins as themonomer for the process of this disclosure are: 1-butene, 1-pentene,1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene,1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene,1-heptadecene, 1-octadecene, 1-nonadecene, and 1-icosene. Still morepreferred linear terminal olefin as monomer for the process of thisdisclosure are: 1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene,1-tetradecene, 1-hexadecene, 1-octadecene, and 1-icosene. Still morepreferred linear terminal olefins as monomer for the process of thisdisclosure are: 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene,1-hexadecene, and 1-octadecene. Linear terminal olefins having evennumber of carbon atoms can be advantageously manufactured by theoligomerization of ethylene, as is typically done in the industry. Manyof these linear terminal olefins with even number of carbon atoms arecommercially available at large quantities.

Branched terminal olefins can be used as the monomer in the process aswell. Particularly useful branched terminal olefins are thoserepresented by the following formula:

where R^(x) and R^(y) are independently any hydrocarbyl group,preferably any C1-C30 alkyl group, more preferably any C1-C30 linearalkyl group, n is an integer, and n≥2, preferably n≥4, more preferablyn≥5. Preferably n≤30, more preferably n≤20, still more preferably n≤15.

The terminal olefin monomer may be fed as a pure material or as asolution in an inert solvent into the continuously operatedoligomerization reactor. Non-limiting examples of the inert solventinclude: benzene, toluene, any xylene, ethylbenzene, and mixturesthereof; n-pentane and branched isomers thereof, and mixtures thereof;n-hexane and branched isomers thereof, and mixtures thereof; cyclohexaneand saturated isomers thereof, and mixtures thereof;

n-heptane and branched isomers thereof, and mixtures thereof; n-octaneand branched isomers thereof, and mixtures thereof; n-nonane andbranched isomers thereof, and mixtures thereof; n-decane and branchedisomers thereof, and mixtures thereof; and any mixture of the above;Isopar® solvent; and the like.

The terminal olefins used herein can be produced directly from ethylenegrowth process as practiced by several commercial production processes,or they can be produced from Fischer-Tropsch hydrocarbon synthesis fromCO/H₂ syngas, or from metathesis of internal olefins with ethylene, orfrom cracking of petroleum or Fischer-Tropsch synthetic wax at hightemperature, or any other terminal olefin synthesis routes. A preferredfeed for this invention is preferably at least 80 wt % terminal olefin(preferably linear alpha olefin), preferably at least 90 wt % terminalolefin (preferably linear alpha olefin), more preferably 100% terminalolefin (preferably linear alpha olefin). The feed olefins can be themixture of olefins produced from other linear terminal olefin processcontaining C4 to C20 terminal olefins as described in Chapter 3 “Routesto Alpha-Olefins” of the book Alpha Olefins Applications Handbook,Edited by G. R. Lappin and J. D. Sauer, published by Marcel Dekker, Inc.N.Y. 1989.

The terminal olefin feed and or solvents may be treated to removecatalyst poisons, such as peroxides, oxygen or nitrogen-containingorganic compounds or acetylenic compounds before being supplied to thepolymerization reactor. The treatment of the linear terminal olefin withan activated 13 Angstrom molecular sieve and a de-oxygenate catalyst,i.e., a reduced copper catalyst, can increase catalyst productivity(expressed in terms of quantity of PAO produced per micromole of themetallocene compound used) more than 10-fold. Alternatively, the feedolefins and or solvents are treated with an activated molecular sieve,such as 3 Angstrom, 4 Angstrom, 8 Angstrom or 13 Angstrom molecularsieve, and/or in combination with an activated alumina or an activatedde-oxygenated catalyst. Such treatment can desirably increase catalystproductivity 2- to 10-fold or more.

Where a substantially pure dimer compound

i.e., a vinylidene olefin having a formula (F-II) where the two R¹groups are identical) is desirable, a single terminal olefin monomer(R—CH═CH₂) can be fed into the oligomerization reactor. Thus, a pure1-octene feed will result in a single C16 dimer vinylidene olefin(7-methylenepentadecane), a pure 1-decene feed will result in a singleC20 dimer vinylidene olefin (9-methylenenonadecane), a pure 1-dodecenefeed will result in a single C24 dimer vinylidene olefin(11-methylenetricosane), a pure 1-tetradecene feed will result in asingle C28 dimer vinylidene olefin (13-methyleneheptacosane).

If two different terminal olefin monomers including a first monomer(R^(a)—CH═CH₂) and a second monomer (R^(b)—CH═CH₂, where R^(b) differsfrom R^(a)) are fed into the oligomerization reactor, multiple differentdimer compounds may be produced at various quantities depending on thedimerization reactivity of them: a first dimer formed from two units ofthe first monomer

corresponding to a vinylidene olefin having a formula (F-II) where thetwo IV groups are identical R^(a)); a second dimer formed from two unitsof the second monomer

corresponding to a vinylidene olefin having a formula (F-II) where thetwo R¹ groups are identical R^(b)), and a third category of dimersformed from one unit of the first monomer and another unit of the secondmonomer

corresponding to vinylidene olefins having formula (F-II) where the twoR¹ groups are different). The third category of dimers can have multipleisomers as shown. By way of example, a terminal olefin feed consistingof 1-decene and 1-dodecene in the continuous process for making thevinylidene olefin having formula (F-II) results in the production of adimer mixture comprising 9-methylenenonadecane, 9-methylenehenicosane,11-methylenehenicosane, and 11-methylenetricosane. To the extent such adimer mixture is acceptable for the intended application, a mixture oftwo (or even more) terminal olefin may be used as a terminal olefin feedinto the oligomerization reactor. In commercial productions, even ahigh-purity terminal olefin feed invariably contains impurities such asother terminal olefins at various concentrations in addition to thepredominant terminal olefin. As a result, various quantities of multipleminor vinylidene olefin dimer olefins may be produced in addition to theintended predominant dimer of the predominant terminal olefin. To theextent the presence of such minor vinylidene dimer olefins at thespecific quantities does not interfere with the intended use of thedimer product, such terminal olefin feed comprising minor quantities ofother terminal olefin(s) than the predominant terminal olefin can betolerated in the continuous process for making the vinylidene olefinhaving formula (F-II).I.2b The Metallocene Compound

The metallocene compound in the catalyst system useful in the continuousprocess for making the vinylidene olefin having formula (F-II) can berepresented by the formula Cp(Bg)_(n)MX₂Cp′, where Cp and Cp′, the sameor different, represents a cyclopentadienyl, alkyl-substitutedcyclopentadienyl, indenyl, alkyl-substituted indenyl,4,5,6,7-tetrahydro-2H-indenyl, alkyl-substituted4,5,6,7-tetrahydro-2H-indenyl, 9H-fluorenyl, and alkyl-substituted9H-fluorenyl; Bg represents a bridging group covalently linking Cp andCp′, and n is zero (0), one (1), or two (2), preferably zero (0) or one(1), more preferably zero (0, i.e., where the metallocene compound isunbridged). Exemplary Bg can be represented by any of (i)

where groups G4 are, the same or different at each occurrence,independently selected from carbon, silicon, and germanium, and each R⁹is independently a C1-C30 substituted or unsubstituted linear, branched,or cyclic hydrocarbyl groups. Preferred R⁹ includes substituted orunsubstituted methyl, ethyl, n-propyl, phenyl, and benzyl. Preferably Bgis category (i) or (ii) above. More preferably Bg is category (i) above.Preferably all R⁹'s are identical.

M represents Hf or Zr. Preferably M is Zr. X, the same or different ateach occurrence, independently represents a halogen such as Cl or ahydrocarbyl such as: linear or branched alkyl group such as methyl,ethyl, n-propyl, isopropyl, n-butyl and branched isomeric group thereof,n-pentyl and branched isomeric group thereof, n-hexyl and branchedisomeric group thereof, n-heptyl and branched isomeric group thereof,n-octyl and branched isomeric group thereof, n-nonyl and branchedisomeric group thereof, n-decyl and branched isomeric group thereof, andthe like; a cycloalkyl group; a cycloalkylalkyl group; analkylcycloalkyl group; an aryl group such as phenyl; an arylalkyl groupsuch as benzyl; an alkylaryl group such as tolyl and xylyl. Preferably Xis methyl or Cl; more preferably X is Cl. Without intending to be boundby a particular theory, it is believed that the use of the metallocenecompound results in the formation of vinylidene olefin in theoligomerization reaction. A more preferred group of metallocene compounduseful for the continuous process for making the vinylidene olefin usedin the process for making gamma-branched alcohol product of thisdisclosure are those unbridged metallocene compounds having a generalformula bisCpMX₂, where bisCp represents two cyclopentadienyl rings, Mis Zr or Hf (preferably Zr), and X is as defined above, but preferablyselected from C1, C1-C10 linear or branched alkyl groups, phenyl, andbenzyl. The most preferred metallocene compound useful in the continuousprocess for making the vinylidene olefin having formula (F-II) isbisCpZrCl₂, which is commercially available and can be represented bythe following formula:

In the in the continuous process for making the vinylidene olefin havingformula (F-II), the terminal olefin monomer (or multiple co-monomers)are fed into the oligomerization reactor at a first feeding rate ofR(to) moles per hour, and the metallocene compound is fed into thereactor at a second feeding rate of R(mc) moles per hour. To achieve ahigh conversion of the terminal olefin monomer and a low selectivity ofthe terminal olefin toward trimer of the monomer of at most 5% (hence ahigh selectivity of the terminal olefin toward dimer) in theoligomerization reaction, it is highly desirable that the ratio of thefirst feeding rate to the second feeding rate R(to)/R(mc) be in therange from x1 to x2, where x1 and x2 can be, independently, 100, 150,200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850,900, 950, or 1,000, as long as x1<x2. Preferably x1=300, and x2=800.More preferably x1=400, and x2=750. Still more preferably x1=500, andx2=750. If the ratio of R(to)/R(mc) is higher than 1,000, the conversionof the terminal olefin monomer in the oligomerization reaction can betoo low. If the ratio of R(to)/R(mc) is lower than 100, the consumptionof the metallocene compound can be too large, which is also undesirable.

It is highly desirable that the metallocene compound is dissolved ordispersed in an inert solvent and then fed into the reactor as asolution or a dispersion. Such inert solvent for the metallocenecompound can be, e.g., benzene, toluene, any xylene, ethylbenzene, andmixtures thereof; n-pentane and branched isomers thereof, and mixturesthereof; n-hexane and branched isomers thereof, and mixtures thereof;cyclohexane and saturated isomers thereof, and mixtures thereof;n-heptane and branched isomers thereof, and mixtures thereof; n-octaneand branched isomers thereof, and mixtures thereof; n-nonane andbranched isomers thereof, and mixtures thereof; n-decane and branchedisomers thereof, and mixtures thereof; and any mixture of the above;Isopar® solvent; and the like.

One or more metallocene compound(s) may be used in the continuousprocess for making the vinylidene olefin having formula (F-II).

I.2c The Alumoxane

The alumoxane used in the process of this disclosure functions asactivator of the metallocene compound and scavenger for impurities (suchas water). Alumoxanes can be obtained by partial hydrolysis of alkylaluminum compounds. Thus, non-limiting examples of alumoxanes useful inthe process of this disclosure include those made by partial hydrolysisof trimethyl aluminum, triethyl aluminum, tri(n-propyl)aluminum,tri(isopropyl)aluminum, tri(n-butyl)aluminum, tri(isobutyl)aluminum,tri-(tert-butyl)aluminum, tri(n-pentyl)aluminum, tri(n-hexyl)aluminum,tri(n-octyl)aluminum, and mixtures thereof. Preferred alumoxane for theprocess of this disclosure is methylalumoxane (“MAO”) made from partialhydrolysis of trimethyl aluminum.

The alumoxane feed supplied into the continuously operatedoligomerization reactor is advantageously substantially free of metalelements other than aluminum, alkali metals, alkaline earth metals, andthe metal(s) contained in the metallocene compound(s) described above.Preferably, the alumoxane feed used in the process of this disclosurecomprises metal elements other than aluminum, alkali metals, alkalineearth metals, Zr, and Hf at a total concentration of no greater than x1ppm by mole, based on the total moles of all metal atoms in thealumoxane feed, where x1 can be 50,000, 40,000, 30,000, 20,000, 10,000,8,000, 6,000, 5,000, 4,000, 2,000, 1,000, 800, 600, 500, 400, 200, 100,80, 60, 50, 40, 20, or even 10. More preferably, the alumoxane feed usedin the process of this disclosure comprises metal elements other thanaluminum, Zr, and Hf at a total concentration of no greater than x2 ppmby mole, based on the total moles of all metal atoms in the alumoxanefeed, where x2 can be 50,000, 40,000, 30,000, 20,000, 10,000, 8,000,6,000, 5,000, 4,000, 2,000, 1,000, 800, 600, 500, 400, 200, 100, 80, 60,50, 40, 20, or even 10. Still more preferably, the alumoxane feed fedinto the reactor is free of all metals other than aluminum and themetal(s) contained in the metallocene compound(s) described above. Ionsor compounds of metal elements other than aluminum, alkali metals andalkaline earth metals can be Lewis acids capable of catalyzing undesiredpolymerization of the terminal olefin monomer, the dimer and higheroligomers, resulting in the production of undesired 1,2-di-substitutedvinylenes and tri-substituted vinylenes. Lewis acids such as metal ionscan also catalyze the isomerization of the terminal olefin monomer andthe isomerization of the vinylidene olefin dimer and higher oligomers,resulting in the production of internal olefin isomers of the terminalolefin monomer, 1,2-di-substituted vinylene and tri-substituted vinylenedimers and higher oligomers, which is undesirable for many applicationsof the oligomer product, including but not limited to the dimer product.

Preferably the alumoxane used in the continuous process for making thevinylidene olefin having formula (F-II) is substantially free of anyLewis acid capable of catalyzing the isomerization of the terminalolefin monomer, isomerization of a vinylidene olefin dimer, andpolymerization of the terminal olefin monomer via mechanism differingfrom the oligomerization catalyzed by the metallocene compound usedherein. For the purpose of this disclosure, the metallocene compound perse, the alumoxane per se, and any variations and derivatives thereofduring the oligomerization reaction are not considered as Lewis acids.

A portion or the entirety of the alumoxane fed into the continuouslyoperated oligomer reactor may be mixed with a portion or the entirety ofthe metallocene compound(s) described above, preferably dissolved and/ordispersed into an inert solvent, before it is fed into the reactor. Insuch case, the stream carrying a portion or the entirety of alumoxanefed into the reactor may contain the metal element(s) contained in themetallocene compound(s).

The alumoxane may be supplied into the reactor as a stream separate fromthe terminal olefin monomer stream and the metallocene compound stream.Alternatively or in addition, at least a portion of the alumoxane may becombined with the terminal olefin monomer and supplied into the reactortogether. Mixing alumoxane with the olefin monomer before being suppliedinto the reactor can result in the scavenging of catalyst poisonscontained in the monomer feed before such poisons have a chance tocontact the metallocene compound inside the reactor. It is also possibleto combine at least a portion of the alumoxane with at least a portionof the metallocene compound in a mixture, and supply the mixture as acatalyst stream into the reactor.

The alumoxane is desirably dissolved or dispersed in an inert solventbefore being fed into the reactor or before being combined with themonomer feed and/or the metallocene compound. Mention of non-limitingexamples of such inert solvent can be made of the following: benzene,toluene, any xylene, ethylbenzene, and mixtures thereof; n-pentane andbranched isomers thereof, and mixtures thereof; n-hexane and branchedisomers thereof, and mixtures thereof; cyclohexane and saturated isomersthereof, and mixtures thereof; n-heptane and branched isomers thereof,and mixtures thereof; n-octane and branched isomers thereof, andmixtures thereof; n-nonane and branched isomers thereof, and mixturesthereof; n-decane and branched isomers thereof, and mixtures thereof;and any mixture of the above; Isopar® solvent; and the like.

I.2d Oligomerization Reaction Conditions

In the continuous process for making the vinylidene olefin havingformula (F-II), the terminal olefin monomer (or multiple co-monomers) isfed into the oligomerization reactor at a first feeding rate of R(to)moles per hour, and the metallocene compound is fed into the reactor ata second feeding rate of R(mc) moles per hour, and the alumoxane is fedinto the reactor at a third feeding rate corresponding to R(Al) moles ofaluminum atoms per hour.

To achieve a high conversion of the terminal olefin monomer and a lowselectivity of the terminal olefin toward trimer of the monomer of atmost 5% (hence a high selectivity of the terminal olefin toward dimer)in the oligomerization reaction, it is highly desirable that the ratioof the third feeding rate to the second feeding rate R(Al)/R(mc) be inthe range from y1 to y2, where y1 and y2 can be, independently, 1.0,1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0,8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0,14.5, 15.0, as long as y1<y2. Preferably y1=2.0, and y2=12.0. Morepreferably y1=2.0, and y2=10.0. Still more preferably y1=2.0, andy2=7.0. Still more preferably y1=2.0, and y2=5.0. If the ratio ofR(Al)/R(mc) is higher than 15.0, selectivity of the terminal olefintoward trimer and higher oligomers can be too high. If the ratio ofR(Al)/R(mc) is lower than 1.0, the conversion of the terminal olefinmonomer in the oligomerization reaction can be too low.

The oligomerization reaction in the process of this disclosureadvantageously is carried out at a mild temperature in the range from t1to t2° C., where t1 and t2 can be, independently, 30, 35, 40, 45, 50,55, 60, 65, 70, 75, 80, 85, or 90, as long as t1<t2. Preferably t1=40,and t2=80. More preferably t1=50, and t2=75. If the temperature is below30° C., the reaction kinetics can be too slow. If the temperature ishigher than 90° C., selectivity of the terminal olefin toward trimer andhigher oligomers can be too high and the catalyst activity may be toolow.

The oligomerization reaction may be carried out at a residence time inthe range from rt1 to rt2 hours, where rt1 and rt2 can be,independently, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0,6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.0, 10, 12, 15, 18, 24, 30, 36, 42, or48, as long as rt1<rt2. Preferably rt1=3 and rt2=8. More preferablyrt1=4 and rt2=8. Still more preferably rt1=5 and rt2=7.

The oligomerization reaction is preferably carried out in the presenceof mechanical stirring of the reaction mixture such that a substantiallyhomogeneous reaction mixture with a steady composition is withdrawn fromthe reactor once the reactor reaches steady state.

Advantageously the oligomerization reaction of the process of thisdisclosure is carried out under mild pressure. Because theoligomerization reaction is sensitive to water and oxygen, the reactoris typically protected by an inert gas atmosphere such as nitrogen. Toprevent air leakage into the reactor, it is desirable that the totalpressure inside the reactor is slightly higher than the ambientpressure.

The oligomerization reaction can be carried out in the presence of aquantity of inner solvent. Non-limiting examples of such solventinclude: benzene, toluene, any xylene, ethylbenzene, and mixturesthereof; n-pentane and branched isomers thereof, and mixtures thereof;n-hexane and branched isomers thereof, and mixtures thereof; cyclohexaneand saturated isomers thereof, and mixtures thereof; n-heptane andbranched isomers thereof, and mixtures thereof; n-octane and branchedisomers thereof, and mixtures thereof; n-nonane and branched isomersthereof, and mixtures thereof; n-decane and branched isomers thereof,and mixtures thereof; and any mixture of the above; Isopar® solvent; andthe like.

Due to the nature of the metallocene compound and the alumoxane used inthe process of this disclosure, in the oligomerization reaction, a highselectivity of the terminal olefin toward vinylidenes olefins (e.g., atleast 95%, 96%, 97%, 98%, or even 99%) and a low selectivity of theterminal olefin toward internal olefins including 1,2-di-substitutedvinylenes and tri-substituted vinylenes (e.g., at most 5%, 4%, 3%, 2%,or even 1%) can be achieved. Thus, the oligomers thus made, especiallythe dimer, tend to be predominantly vinylidene and can be advantageouslyused as a vinylidene without further purification in applications wherevinylidenes are desired.

As a result of the use of a continuous process, and the use of ametallocene compound and an alumoxane in the respective quantitiesabove, we were able to achieve extremely low selectivity of the terminalolefin of the terminal olefin monomer toward trimer in theoligomerization reaction of at most 5%, thereby achieving a highselectivity of the terminal olefin toward the intended dimer. In certainembodiments, selectivity of the terminal olefin toward trimer can reachno greater than 4%, no greater than 3%, no greater than 2%, or even nogreater than 1%. At such low selectivity of the terminal olefin towardtrimer, selectivity of the terminal olefin toward tetramer and evenhigher oligomers are even lower and in many embodiments negligible.Thus, in the oligomerization reaction of the process of this disclosure,the selectivity of the terminal olefin toward tetramer and higheroligomers is typically no greater than 2%, or no greater than 1%, or nogreater than 0.5%, or even no greater than 0.1%. Thus, in theoligomerization reaction of the process of this disclosure, theselectivity of the terminal olefin toward dimer can be at least 90% (or≥91%, ≥92%, ≥93%, ≥94%, ≥95%, ≥96%, ≥97%, ≥98%, or even ≥99%).

In addition to the high selectivity of the terminal olefin monomertoward dimer in the oligomerization reaction, the process of thisdisclosure also exhibits a high conversion of the terminal olefinmonomer, e.g., a conversion of at least 40%, 45%, 50%, 55%, 60%, 65%, or70%, can be achieved in a single pass oligomerization reaction. Withrecycling of unreacted monomer separated from the oligomerizationreaction mixture to the oligomerization reactor, the overall conversioncan be even higher, making the process of this disclosure particulareconomic.

Because the alumoxane introduced into the reaction system in the processof this disclosure is substantially free of metals other than aluminum,metals contained in the metallocene compound, alkali metals, andalkaline earth metals, the terminal olefin monomer does not undergosignificant isomerization reaction. Likewise, the isomerization of thevinylidene dimers and higher oligomers to form 1,2-di-substitutedvinylene and tri-substituted vinylene is substantially avoided as well.

I.2e Post-Oligomerization Treatment

The oligomerization reaction mixture stream withdrawn from the reactortypically comprises the unreacted terminal olefin monomer, the intendeddimer, trimer, tetramer and higher oligomers, the metallocene compound,the alumoxane, and optional solvent.

Once the oligomerization reaction mixture stream leaves the reactor,typically a stream of quenching agent is injected into the stream toterminate the oligomerization reactions. Non-limiting examples ofquenching agents include: water, methanol, ethanol, CO2, and mixturesthereof. A particularly desirable quenching agent is water.

The metal elements contained in the oligomerization mixture, includingaluminum and Zr or Hf, needs to be removed from the mixture. Removalthereof can be achieved through mechanical filtration using a filtrationaid such as Celite. Presence of aluminum in the liquid mixture can causeisomerization of the monomer and dimer during subsequently processingsteps, such as distillation to remove the unreacted monomers and theoptional distillation to remove higher oligomers such as trimers andtetramers in rare cases where the purity requirement for the dimer is sohigh that even the small quantity of trimer and higher oligomersproduced in the continuous process for making the vinylidene olefinhaving formula (F-II) is considered excessive. It is highly desirablethat upon filtration, the liquid mixture contains aluminum at aconcentration no higher than 50 ppm by weight (preferably no higher than30 ppm, still more preferably no higher than 20 ppm, still morepreferably no higher than 10, still preferably no higher than 5 ppm),based on the total weight of the liquid mixture.

Upon filtration, a mixture comprising monomer, the desired dimer, thetrimer and higher oligomers and the optional solvent is obtained. Themonomer and solvent can be removed by flashing or distillation at anelevated temperature and/or optionally under vacuum. Becauseisomerization of the monomer is avoided in (i) in the oligomerizationreaction due to the lack of Lewis acid capable of catalyzingisomerization reaction and (ii) in the flashing/distillation step due tothe removal of aluminum and other metal elements from the liquid mixtureat the earlier filtration step, the monomer reclaimed form the mixtureconsists essentially of the terminal olefin monomer as introduced intothe reactor. As such, the reclaimed monomer can be recycled to theoligomerization reactor as a portion of the monomer stream. The thusobtained oligomer mixture absent monomer and solvent may be used as avinylidene dimer olefin product as is due to the low percentage oftrimer and higher oligomers. For certain applications where even higherpurity of the dimer is desirable, one can remove the timer and higheroligomers by further separation such as distillation.

I.2f The Vinylidene Dimer Product

The dimer product as a result of the continuous process for making thevinylidene olefin having formula (F-II) advantageous comprises dimer(s)of the monomer(s) as the predominant component, and trimers at aconcentration no higher than 5 wt % (preferably ≤4 wt %, ≤3 wt %, ≤2 wt%, ≤1 wt %, or even ≤0.5 wt %), based on the total weight of the dimerproduct. Advantageously, the dimer product comprises dimer at aconcentration of at least 90% (or ≥91%, ≥92%, ≥93%, ≥94%, ≥95%, ≥96%,≥97%, ≥98%, or even ≥99%), based on the total weight of the dimerproduct.

The dimer product as a result of the continuous process for making thevinylidene olefin having formula (F-II) can advantageous comprisevinylidene(s) at a total concentration of at least 95 wt % (preferably≥96 wt %, ≥97 wt %, ≥98%, or even ≥99 wt %), based on the total weightof the dimer product.

The vinylidene dimer product obtainable from the process of thisdisclosure can advantageously comprise one of the following compounds ata concentration of at least 95 wt %, at least 96 wt %, at least 97 wt %,at least 98 wt %, or even at least 99 wt %, based on the total weight ofthe dimer product, if a substantially pure terminal olefin (with aconcentration of at least 95 wt %, 96 wt %, 97 wt %, 98 wt %, or 99 wt %of the terminal olefin, based on the total weight of the terminalolefins included in the monomer feed) is utilized as the monomer feed:3-methylenepentane (from 1-butene); 4-methylenenonane (from 1-pentene);5-methyleneundecane (from 1-hexene); 6-methylenetridecane (from1-heptene); 7-methylenepentadecane (from 1-octene);8-methyleneheptadecane (from 1-nonene); 9-methylenenonadecane (from1-decene); 11-methylenetricosane (from 1-dodecene);13-methyleneheptacosane (from 1-tetradecene); 15-methylenehentriacontane(from 1-hexadecene); 17-methyleneheptatriacontane (from 1-octadecene);and 19-methylenenonatriacontane (from 1-iscocene).

The high-purity, predominantly dimer, predominantly vinylidene productresulting from the continuous process for making the vinylidene olefinhaving formula (F-II) can then be advantageously used as is as ahigh-purity organic compound in many applications, including in thehydroformylation reaction to make the gamma-branched alcohol in thisdisclosure.

II. Hydroformylation of the Vinylidene Olefin Feed to Make theGamma-Branched Alcohol Product

U.S. Pat. No. 8,383,869 B2 discloses a process for making gamma-branchedalcohols from a terminal olefin including a first step of producing avinylidene dimer of the terminal olefin, followed by hydroformylation ofthe vinylidene dimer. This patent teaches that in the hydroformylationprocess, multiple alcohol isomers will be produced (lines 30-36, column4). Because the isomers have the same molecular weight and similarmolecular structure, it follows from the teaching in U.S. Pat. No.8,383,869 that it would be very difficult to produce one gamma-branchedalcohol at high purity by hydroformylation of a vinylidene olefin.JP2005-298443A discloses a similar process for making gamma-branchedalcohols from alpha-olefin. While a high purity of a gamma-branchedalcohol was reportedly produced in an example in this patent publicationby using a cobalt-containing carbonylation catalyst, the purity stillhas room for improvement. In addition, the overall yield of thegamma-branched alcohol product from the terminal olefin as disclosed inJP2005-298443A has room for improvement as well.

The present inventors have surprisingly found that by using aRh-containing carbonylation catalyst in combination with a phosphinecompound, one can produce gamma-branched alcohols having formula (F-I)at an exceedingly high selectivity, significantly higher than thatdisclosed in JP2005-298443A, and contrary to the teaching in U.S. Pat.No. 8,383,869.

II.1 The Rh-Containing Compound

In the carbonylation step, the vinylidene olefin molecule reacts with COand H2 to product a carbonylated derivative of the vinylidene. Withoutintending to be bound by a particular theory, it is believed that analdehyde is formed as a result.

Examples of the Rh-containing compound include the following of rhodiumat any oxidative state (e.g., (I), (II) or (III)) and mixtures thereof:oxides; inorganic salts such as rhodium fluoride, rhodium chloride,rhodium bromide, rhodium iodide, rhodium nitrate, and rhodium sulfate;rhodium salts of carboxylic acids such as rhodium acetate, di-rhodiumtetracetate, rhodium acetylacetonate, rhodium(II) isobutyrate,rhodium(II) 2-ethylhexanoate; rhodium carbonyl compounds such asRh₄(CO)₁₂, Rh₆(CO)₁₆, (acetylacetonato)dicarbonylrhodium(I),chlorodicarbonylrhodium dimer, chlorobis(ethylene)rhodium dimer,hexarhodiumhexadecylcarbonyl, tetrarhodiumdodecylcarbonyl, and the like.

Exemplary catalytically effective amount of the Rh-containing compoundcan range from n1 to n2 micromoles of the Rh-containing compound permole of the vinylidene olefin to be converted, where n1 and n2 can be,independently, 200, 250, 300, 350, 400, 450, 500, 550, 650, 700, 750,800, 850, 900, 950, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600,1,700, 1,800, 1,900, 2,000, 2,100, 2,200, 2,300, 2,400, 2,500, 2,600,2,700, 2,800, 2,900, or 3,000, as long as n1<n2. Preferably n1=300 andn2=2500. More preferably n1=500 and n2=2,000. Still more preferablyn1=600, and n2=1,800.

A portion of the Rh-containing compound can be solubilized in an inertsolvent, or dispersed in an inert liquid medium and then introduced intothe reaction system. Alternatively or additionally, a portion of theRh-containing compound can be dispersed in the vinylidene olefin to beconverted as a suspension to effect the catalytic effect. In the lattercase, it is highly desirable that the reactor is equipped with amechanical stirrer, such that the reaction is conducted with continuousstirring to achieve a uniform distribution of the Rh-containing compoundin the reaction media.

Cobalt-containing compounds were used previously to catalyze thecarbonylation of olefin compounds. However, in the process of thisdisclosure, in order to achieve a high selectivity of the vinylideneolefin toward the desired carbonylation conducive for the production ofa gamma-branched alcohol, an Rh-containing compound is used instead.

II.2 The Phosphine Compound

Presence of a phosphine compound in the reaction system is important fora high selectivity toward the desired carbonylation reaction leading toa high-purity gamma-branched alcohol product having formula (F-I). As isdemonstrated in the examples, Part B of this disclosure, without thepresence of a phosphine compound in the reaction system, a plurality ofalcohols can be produced; and on the other hand, when a phosphinecompound is included, the hydroformylation is highly selective towardthe desired gamma-branched alcohol having formula (F-I).

Non-limiting examples of useful phosphine compounds in thehydroformylation of vinylidene olefin in the process of this disclosureinclude: triphenyl phosphine; tri-(n-butyl) phosphine; tri-(tert-butyl)phosphine; tri-(n-pentyl) phosphine; tri-(n-hexyl) phosphine;tri(n-heptyl) phosphine; tri-(n-octyl) phosphine; tri(n-nonyl)phosphine; tri-(n-decyl) phosphine; and any mixture of two or morethereof, and the like.

Exemplary catalytically effective amount of the phosphine compound canrange from n1 to n2 micromoles of the phosphine compound per mole of thevinylidene olefin to be converted, where n1 and n2 can be,independently, 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500,5,000, 5,500, and 6,000, as long as n1<n2. Preferably n1=1,500 andn2=5000. More preferably n1=2,000 and n2=4,000.

Without intending to be bound by a particular theory, it is believedthat the phosphine compound introduced into the carbonylation reactionmixture functions as a ligand to the Rh atom contained in theRh-containing compound during reaction, which favorably catalyzes thedesired carbonylation conducive to the formation of the gamma-branchedalcohol of this disclosure when the carbonylated product from thevinylidene is reduced to produce an alcohol.

The phosphine compound may be introduced into the carbonylation reactorseparately from the Rh-containing compound. Alternatively oradditionally, a portion of the phosphine compound may be combined with aportion of the Rh-containing compound to form a mixture comprising arhodium-phosphine compound complex and then the mixture is introduced into the carbonylation reactor.

II.3 The Carbonylation Reaction

The carbonylation reaction of the vinylidene olefin is desirablyconducted in the presence of an atmosphere comprising CO and hydrogenpreferably at a molar ration of 1:1 at an absolute total partialpressure of CO and H₂ in a range from p1 to p2 MPa (million Pascal),where p1 and p2 can be, independently, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5,4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, or 10, aslong as p1<p2. Preferably p1=1.5 and p2=7.0. More preferably p1=2.0 andp2=6.0. A high total partial pressure of CO/H₂ is conducive to a highconversion of the vinylidene. Desirably, the conversion of vinylidene inthe carbonylation reaction is at least 70%, preferably at least 80%,more preferably at least 90%, still more preferably at least 95%.

The carbonylation reaction of the vinylidene olefin is desirablyconducted at a relatively mild temperature in a range from t1° C. to t2°C., where t1 and t2 can be, independently, 40, 45, 50, 55, 60, 70, 80,90, 100, 110, 120, 130, 140, 150, 160, 170, or 180, as long as t1<t2.Preferably t1=60 and t2=150. More preferably t1=80 and t2=120. A highertemperature is conductive to a higher conversion and a higher reactionrate, but at the expense of selectivity toward the desired carbonylatedcompound derived from the vinylidene olefin. Reaction time can rangefrom 0.5 hour to 96 hours, preferably 1 hour to 60 hours, morepreferably no longer than 48 hours, still more preferably no longer than36 hours, still more preferably no longer than 24 hours, still morepreferably no longer than 12 hours, still more preferably no longer than6 hours.

Given the high-pressure reaction condition, it is highly desired thatthe carbonylation is conducted in a batch reactor that can withstand ahigh internal pressure. At the end of the reaction, the reactor iscooled down and depressurized, and the carbonylation product mixture,comprising unreacted vinylidene olefin, catalyst, the desiredcarbonylated product, and other undesired by-products, can beadvantageously reduced in the next step without the need ofpurification.

The carbonylation reaction of the vinylidene can be advantageouslyconducted with or without an inert solvent. Inert solvent useful in thisstep include but are not limited to: n-pentane and branched isomersthereof, and mixtures thereof; n-hexane and branched isomers thereof,and mixtures thereof; cyclohexane and saturated isomers thereof, andmixtures thereof; n-heptane and branched isomers thereof, and mixturesthereof; n-octane and branched isomers thereof, and mixtures thereof;n-nonane and branched isomers thereof, and mixtures thereof; n-decaneand branched isomers thereof, and mixtures thereof; and any mixture ofthe above, and the like.

II.4 Reduction of the Carbonylation Product Mixture

Reduction of the carbonylated derivative (such as an aldehyde) of thevinylidene olefin obtained in the carbonylation step results in theformation of the gamma-branched alcohol having a formula (F-I).

Such reduction can be effected by combining the carbonylation productmixture (after removal of solid materials by, e.g., filtration) with areducing agent under reducing conditions. Non-limiting examples of thereducing agent include: NaHB₄, NaAlH₄, and LiAlH₄.

A preferred reducing agent useful in the process of this disclosure ismolecular hydrogen. Reduction by contacting hydrogen can be effected inthe presence of a hydrogenation catalyst under hydrogenation conditions.The hydrogenation catalyst can advantageously comprises a hydrogenationmetal such as Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt, and combinationsthereof preferably supported on an inorganic substrate such as activatedcarbon, silica, alumina, and the like. Hydrogenation conditions caninclude a hydrogen partial pressure in a range from p3 to p4 MPa, wherep3 and p4 can be, independently, 5.0, 6.0, 7.0, 8.0, 9.0, 10, 11, 12,13, 14, 15, 16, 17, 18, 19, or 20, as long as p3<p4. Preferably p3=7 andp4=18. More preferably p3=8 and p4=15. Hydrogenation conditions canfurther include a hydrogenation temperature in the range from t3 to t4°C., where t3 and t4 can be, independently, 50, 60, 70, 80, 90, 100, 110,120, 130, 140, 150, 160, 170, 180, 190, or 200, as long as t3<t4.Preferably t3=60 and t4=180. More preferably t3=70 and t4=150.

The hydrogenation reaction may be conducted with or without the presenceof an inert solvent. Non-limiting examples of inert solvent useful forthis step include: n-pentane and branched isomers thereof, and mixturesthereof; n-hexane and branched isomers thereof, and mixtures thereof;cyclohexane and saturated isomers thereof, and mixtures thereof;n-heptane and branched isomers thereof, and mixtures thereof; n-octaneand branched isomers thereof, and mixtures thereof; n-nonane andbranched isomers thereof, and mixtures thereof; n-decane and branchedisomers thereof, and mixtures thereof; and any mixture of the above, andthe like.

At the end of the reduction reaction, it is highly desired thatsubstantially all of the carbonylated derivative(s) from the vinylideneolefin present in the carbonylation product mixture is converted toalcohol(s). Any olefins, including unreacted vinylidene olefin, presencein the carbonylation product mixture, are also hydrogenated intocorresponding alkanes. Thus, a hydrogenation product mixture comprisingthe desired gamma-branched alcohol and byproducts such as alkane of thevinylidene olefin is obtained at the end of the hydrogenation reaction.

The hydrogenation product mixture can be separated to remove the lightcomponents such as alkane of the vinylidene olefin to obtain an alcoholproduct comprising primarily the intended gamma-branched alcohol.

In the process of this disclosure, as a result of the use of aRh-containing carbonylation compound and the phosphine compound in thereaction system, a high selectivity of the desired gamma-branchedalcohol can be achieved in the hydroformylation process, resulting in analcohol product having a purity of the desired gamma-branched alcoholafter removal of the alkane but before the removal of components heavierthan the gamma-branched alcohol of at least 96 wt %, or at least 97 wt %or at least 98 wt %, or even at least 99 wt %, based on the total weightof the alcohol product.

If components heavier than the intended gamma-branched alcohol arepresent at quantities higher than a level acceptable for the intendedapplication of the alcohol, one may further purify the product by usingone or more of distillation, adsorption, liquid chromatography, gaschromatography, and the like, to obtain a substantially puregamma-branched alcohol product having formula (F-I).

The combination of the hydroformylation process of this disclosure withthe continuous process for making high-purity vinylidene olefin dimer ofa terminal olefin monomer described in detail above can result in a highconversion, high selectivity process for making the desiredgamma-branched alcohol from a terminal olefin feed and CO/H2 syngasmixture.

Commercially available terminal olefins useful in the process of thisdisclosure include but are not limited to: 1-butene, 1-pentene,1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene,1-octadecene, and the like. They can be conveniently used to fabricategamma-branched alcohol 3-ethylheptan-1-ol, 3-propyloctan-1-ol,3-butylnonan-1-ol, 3-hexylundecan-1-ol, 3-octyltridecan-1-ol,3-decylpentadecan-1-ol, 3-dodecylheptadecan-1-ol,3-tetradecylnonadecan-1-ol, 3-hexadecylhenicocan-1-ol, and3-octadecyltricosan-1-ol, respectively.

Preferred examples of gamma-branched alcohols that can be made by theprocess of this disclosure include the following: 3-ethylheptan-1-ol;3-propyloctan-1-ol, 3-butylnonan-1-ol; 3-hexylundecan-1-ol;3-octyltridecan-1-ol; 3-decylpentadecan-1-ol; and3-dodecylheptadecan-1-ol.

The present invention is further illustrated by the followingnon-limiting examples.

EXAMPLES

Part A: Dimerization of Terminal Olefins to Make Vinylidene Olefins

Example A1: Dimerization of 1-Tetradecene in a Continuous Reactor

Into a 2-gallon (6.56-liter) continuously stirred tank reactor wascontinuously fed 1-tetradecene feed (containing 98.6 wt % 1-tetradecene,0.7 wt % 1-dodecene and 0.7 wt % of 1-hexadecene, and trace amounts of1-octene and 1-decene) at a feeding rate of 3.3 moles per hour,bisCpZrCl₂ (dissolved or dispersed in toluene at a concentration of 1.4wt %) at a feeding rate of 0.0048 mole per hour, and MAO (dissolved ordispersed in toluene at a concentration of 10 wt % at a feeding rate of0.022 mole aluminum atoms per hour, operating at a constant temperatureof 70° C. and residence time of 8.0 hours. The product mixture effluentexiting the reactor was immediately quenched by injectingroom-temperature water at a feeding rate of 2 milliliter per hour.Filter aid was then added into the quenched product mixture. Theresultant mixture was then filtered to remove solids to obtain a liquid.The liquid was then measured by gas chromatography to show a conversionof 1-tetradecene in the reaction of 71%. The liquid was then vacuumdistilled at an absolute pressure of 4 mmHg (533 Pascal) to obtain aclear residual liquid as the final product. The final product was thencharacterized by gas chromatography to show the following composition,with total concentration of dimers at 98.84 wt %.

Components Concentration (wt %) C14 monomer <0.10 Dimers C16-C26 1.69C28-C32 97.15 C16-C32 98.84 Trimers (C36-C48) 0.86 Tetramers (C48-C64)0.24

The final product was then characterized by ¹H NMR. Data show that thefinal product was predominantly 13-methyleneheptacosane. Data showed thepresence of vinyls, vinylidenes, 1,2-di-substituted vinylenes, andtri-substituted vinylenes. The vinyls are attributed to residual1-tetradecene monomer. The remaining olefin types (1,2-di-substitutedvinylenes, tri-substituted vinylenes, and vinylidenes) were normalizedto sum up to 100%. Their respective distributions are given below:

Olefin Type Concentration (mol %) 1,2-Di-substituted Vinylenes 1.1Tri-substituted Vinylenes 1.1 Vinylidenes 97.8

Clearly, in the CSTR process of this Example A1, a high-purity,predominantly vinylidene olefin dimer product was produced. Because ofthe low concentrations of heavy components such as trimers andtetramers, the final product can be used as a vinylidene olefin dimerfor many applications without further distillation to remove the heavycomponents. The overall conversion of the monomer at 71% without recycleis quite high. The very low distribution of 1,2-di-substituted vinylenesand tri-substituted vinylenes in the final product indicates thatisomerization of the vinylidene olefin dimer into either of thevinylenes occurred at an extremely low level, if at all. This is due inpart to the lack of metal elements other than aluminum and zirconiumthat may function as a Lewis acid capable of catalyzing theisomerization of vinyls and vinylidenes to produce vinylenes. Asdiscussed below, it is believed that the presence of metal ions such asCu²⁺ in the reaction system, which can serve as Lewis acids, can lead todimerization of the terminal olefin through mechanism different fromthat catalyzed by a metallocene compound, resulting in the production ofvinylenes and branched oligomers, which is highly undesirable.

Example A2: (Comparative): Dimerization of 1-Tetradecene in a BatchReactor

Into a 2-gallon (6.56-liter) batch reactor equipped with mechanicalstirring was charged 2.2 grams (0.0076 moles) bisCpZrCl₂ (dissolved ordispersed in toluene at a concentration of 1 wt %), followed by 1.74grams of MAO (corresponding to 0.030 moles of aluminum atoms) dissolvedor dispersed in toluene at a concentration of 10 wt %, and lastly added4.4 kilograms (22.4 moles) of 1-tetradecene feed (containing 98.6 wt %1-tetradecene, 0.7 wt % 1-dodecene and 0.7 wt % of 1-hexadecene, andtrace amounts of 1-octene and 1-decene) over a period of 90 minutes. Thereactor was then operated at a constant reaction temperature of 70° C.for a batch reaction period of 6.0 hours. The product mixture at the endof the reaction period was immediately quenched by injecting 3 grams ofwater. Filter aid was then added into the quenched product mixture. Theresultant mixture was then filtered to remove solids to obtain a liquid.The liquid was then measured by gas chromatography to show a conversionof 1-tetradecene in the reaction to oligomers of 37%. The liquid wasthen vacuum distilled at an absolute pressure of 10 mmHg (1333 Pascal)to remove residual monomer and to obtain a clear residual liquid as thefinal product. The final product was then characterized by gaschromatography to show the following composition, with a totalconcentration of dimers at 95.42 wt %:

Components Concentration (wt %) Dimers C16-C26 2.19 C28-C30 93.23C16-C30 95.42 Trimers (C36-C48) 3.26 Tetramers (C48-C64) 1.32

In the batch process of this comparative Example A2, the conversion ofthe linear terminal olefin monomer was much lower than in the continuousprocess of Example A1, even though the overall loading of themetallocene compound and MAO were comparable. In addition, the finalproduct after the removal of residual monomer resulting from this batchprocess also contained trimers and tetramers at concentrations more thantwice that in the final product from the continuous process of ExampleA1. The continuous process of Example A1 was far superior in producing ahigh-purity vinylidene olefin dimer product from a linear terminalolefin such as 1-tetradecene.

Example A3: (Comparative): Dimerization of 1-tetradecene in a BatchReactor

This experiment was carried out in substantially the same manner andsequence as in comparative Example A2, with the exception that themonomer feed was added first, followed by the addition of MAO solutionat the same quantity and a holding period of 1 hour, before themetallocene compound solution at the same quantity was finally added.Catalyst loadings, temperature and reaction time remained the same as inExample A2. The conversion of monomer to oligomer product was measuredto be 59%, slightly higher than Example A2, but still much lower than inExample A1. The final product was measured to have the followingcomposition:

Components Concentration (wt %) Dimers C16-C26 1.65 C28-C30 84.42C16-C30 86.07 Trimers (C36-C48) 6.25 Tetramers (C48-C64) 7.68

In this batch process of comparative Example A3, selectivity of theterminal olefin toward dimers in the reaction was reduced to a mere86.07%, resulting in large quantities of trimers and tetramers in thefinal product, which would have to be removed by distillation in orderfor the dimer to be useful as a pure product for many applications.

Example A4: (Comparative): Dimerization of 1-Decene in a Batch Reactor

Into a 2-gallon (6.56-liter) batch reactor equipped with mechanicalstirring was charged 5 kilograms (26 moles) of 1-decene feed (containing98.8 wt % 1-decene, 0.5 wt % 1-octene, 0.7 wt % 1-dodecene, and traceamounts of 1-hexene and 1-tetradecene), followed by 5 grams MAO(corresponding to 0.086 moles Al atoms) dissolved or dispersed intoluene at a concentration of 10 wt %, and finally 6.3 grams (0.022moles) bisCpZrCl₂ dissolved or dispersed in toluene at a concentrationof 1.4 wt %, and held at a constant reaction temperature of 80° C. for abatch reaction period of 6.0 hours. The product mixture at the end ofthe reaction period was immediately quenched by injection of 10 grams ofwater. Filter aid was then added into the quenched product mixture. Theresultant mixture was then filtered to remove solids to obtain a liquid.The liquid was then measured by gas chromatography to show a conversionof monomers in the reaction to oligomers of 77%. The liquid was thendistilled under a vacuum of an absolute pressure of 10 mmHg (1333Pascal) to remove residual monomer and to obtain a clear residual liquidas an intermediate product. The intermediate product was thencharacterized by gas chromatography to show the following composition:

Components Concentration (wt %) C20 Dimers 79.23 C30 Trimer 4.72 C40Tetramer 16.05

In the batch process of this comparative Example A4, the conversion ofthe linear terminal olefin monomer was much lower than in the continuousprocess of Example A1, even though the overall loading of themetallocene compound and MAO were comparable. In addition, theintermediate product after the removal of residual monomer resultingfrom this batch process also contained trimers and tetramers at aconcentration more than ten times that in the final product from thecontinuous process of Example A1. Such large quantity of trimer andtetramers render the intermediate product not useable directly as adimer product for many applications. The continuous process of ExampleAl was far superior in producing a high-purity vinylidene olefin dimerproduct from a linear terminal olefin.

A further step of distillation of the intermediate product was thenperformed to remove the heavy trimer and tetramer to obtain a finalproduct of C20 dimer having the following composition as measured by gaschromatography:

Component Concentration (wt %) C20 dimer 99.36 C30 trimer 0.56 C40tetramer 0.08

The final product in this example was characterized by 1H-NMR todetermine the distribution of olefin types. Vinyls were quantified fromthe NMR spectra but assumed to be from residual monomer. Thedistribution of vinylidenes, 1,2-di-substituted vinylenes andtri-substituted vinylenes in the oligomers are as follows:

Components Concentration (mol %) 1,2-Di-substituted Vinylenes 1.2Tri-substituted Vinylenes 0.7 Vinylidenes 98.1

Thus, in the batch process of this Example A4, exceedingly lowdistribution of 1,2-di-substituted vinylene and tri-substituted vinylenewere produced. Without intending to be bound by a particular theory, itis believed that this is due to the lack of metal ions and Lewis acidsother than the MAO and the metallocene compounds in the reaction system,and the hence the lack of isomerization of the terminal olefin monomerand the vinylidene olefin dimer that may be otherwise catalyzed by thepresence of other Lewis acids.

U.S. Pat. No. 4,658,708 disclosed multiple examples in which a 1-olefin(such as propylene, 1-hexene, and 1-octene) was oligomerized in thepresence of bisCpZrCl₂ and MAO to produce a dimer product withimpressive selectivity toward dimers. Many examples in this patentreference showed significant isomerization of the 1-olefin to produceits isomer 2-olefin. No distribution data of the vinylidenes,1,2-di-substituted vinylenes and tri-substituted vinylenes in the finalproduct were given in the examples in this patent. The high level ofisomerization of the 1-olefin indicates that there is a high likelihoodthat the vinylidene olefin dimer and higher oligomers isomerized to form1,2-di-substituted vinylenes and tri-substituted vinylenes atsignificant quantities. The cause of the isomerization is highly likelythe presence of CuSO₄ in the reaction systems, which was derived fromthe CuSO₄.5H₂O used for making the MAO. The Cu²⁺ in CuSO₄, a Lewis acid,catalyzed the isomerization of the 1-olefin to form 2-olefin isomer, theisomerization of vinylidene oligomers to form 1,2-di-substitutedvinylenes and tri-substituted vinylenes, and likely the polymerizationof the 1-olefins by mechanism different from that catalyzed bybisCpZrCl₂, again resulting in the formation of 1,2-di-substitutedvinylenes and tri-substituted vinylenes.

None of the examples in U.S. Pat. No. 4,658,708 used a continuousprocess.

Part B: Hydroformylation of Vinylidene Olefins to Make Gamma-BranchedAlcohols

Example B1: Synthesis of 3-Octyltridecan-1-ol B1a. Synthesis of9-Methylenenonadecane

Into a batch reactor was charged 5000 grams of 1-decene (98.6% 1-decene,0.7% 1-octene, 0.7% 1-dodecene), into which 50 grams of 10% MAO solutionwas added and held for 60 minutes at 80° C. 450 grams of catalystsolution (1.4 wt % biscyclopentadienyl zirconium (IV) dichloridedissolved in toluene) was subsequently added over 52 minutes. Thereactor was held at 80° C. for 6 hours before the reaction was cooledand quenched with 10 mL of water. Gas chromatography showed reactorconversion was 74% with 88% selectivity to dimer and 12% selectivity totrimer and heavier species.

Filter aid was added thereafter into the fluid, which was filtered toremove Zr and/or Al-containing solid particles. The resultant mixturewas then flashed to remove the residual monomer and distilled to removeheavies product to isolate the dimer species. The recovered dimerproduct was measured to contain dimers of the starting olefin at aconcentration of 99.5 wt % by GC and a concentration of9-methylenenonadecane at 98 mol % (by ¹H NMR).

B1b. Synthesis of 3-Octyltridecan-1-ol by Hydroformylation in thePresence of a Rh-Containing Compound and Triphenyl Phosphine

B1b-I: Carbonylation of 9-Methylenenonadecane

Into a 1-gallon autoclave equipped with mechanical stirrer, 3.24 gramsof (acetylacetonato)dicarbonylrhodium and 4.87 grams of triphenylphosphine (together “Catalyst”) was mixed with 2000 grams of the9-methylenenonadecane-containing dimer product made in step B1a above toform a slurry. The reaction system was nitrogen purged and then purgedwith syngas (1:1 molar ratio H₂:CO). The autoclave was pressurized bysyngas to 510 psig (3516 kPa, gauge pressure) at 26° C., where agitationbegun. Under agitation and constant pressure, temperature was thenraised from 26° C. to 100° C. Syngas pressure inside the autoclave wasthen raised to 700 psig (4826 kPa, gauge pressure) at this temperatureand held under constant pressure and temperature for 18 hours before itwas depressurized. The reaction product mixture, a dark liquid, was thendischarged and filtered to remove solid particles and obtain a carbonylproduct mixture. Olefin conversion in this step was measured to be 92.1%with selectivity to C21 carbonyl product estimated at 99%. Infraredabsorption spectra of the carbonyl product mixture with an overlay ofthat of the 9-methylenenonadecane-containing dimer product made in stepB1a showed the formation of a peak at 1729.83 cm⁻¹, indicating theformation of an aldehyde.

B1b-II: Hydrogenation of the Carbonyl Product Mixture

Into a 1-gallon autoclave equipped with mechanical stirrer, the carbonylproduct mixture made in step B1b-I above and 27.5 grams of Pt/C catalystwere charged to make a slurry. The autoclave was first purged threetimes with nitrogen. Next, the autoclave was pressured up with 100% H₂to 500 psig (3447 kPa, gauge pressure) and the temperature increased to50° C. The pressure and temperature were then slowly ramped to 100° C.and 1500 psig (10,342 kPa, gauge pressure) over 2 hours. Then, thepressure and temperature was finally increased to 150° C. and 2250 psig(15,513 kPa, gauge pressure) over one hour. The reactor was held atthese conditions for 72 hours and then depressurized. The resultantslurry was filtered by vacuum filtration to obtain a crude alcoholmixture. Extent of hydrogenation was measured to be 97.9% with a yieldof heavy fractions (fractions having normal boiling points higher thanthat of 3-octyltridecan-1-ol) at 7.9%.

B1b-III: Distillation to Obtain High-Purity 3-Octyltridecan-1-ol

The crude alcohol mixture produced from step B1b-II above was distilledto remove light fractions (fractions having normal boiling points lowerthan that of 3-octyltridecan-1-ol, such as 9-methylnonadecane) andundesired heavy fractions from the hydrogenated alcohol product toproduce a high-purity fraction of 3-octyltridecan-1-ol (the“C21-alcohol”). The C21-alcohol purity was measured to be 98.2 wt %,with the balance being predominantly 9-methylnonadecane resulting fromthe hydrogenation in step B1b-II of the residual 9-methylenenonadecanefrom step B1b-I. ¹³C NMR of the C21-alcohol, included in FIG. 1, showsthe alcohol is pure 3-octyltridecan-1-ol with a purity of higher than99.9% based on the total weight of the alcohol product excluding9-methylnonadecane. Gas chromatography of the C21-alcohol productproduced in this step, included in FIG. 2, showed a single, tall peak,indicating a high-purity compound is included.

The C21-alcohol was measured to have the following properties: a KV100of 4.18 cSt, a KV40 of 31.4 cSt, a viscosity index of −60.4, a flashpoint determined pursuant to ASTM D93 of 193° C., a density determinedpursuant to ASTM D-4052 of 0.84 gram·cm⁻³, and a refractive indexdetermined pursuant to ASTM D-1218 of 1.453.

Example B2: (Comparative): Synthesis of 3-Octyltridecan-1-ol byHydroformylation in the Presence of a Rh-Containing Compound and in theAbsence of Triphenyl Phosphine Step B2a: Carbonylation of9-methylenenonadecane in the Presence of a Rh-Containing Compound and inthe Absence of Triphenyl Phosphine

In a 1 gallon (3.78 liter) autoclave, 1.13 g of(acetylacetonato)dicarbonylrhodium was slurried to 2000 grams of thedimer product made in step B1a of Example B1 above. Triphenyl phosphinewas not added into the reaction mixture. The reaction system wasnitrogen purged and then purged with syngas (1:1 molar ratio H₂:CO).Pressure inside the reactor was brought up by syngas to 200 psig (1,379kPa, gauge pressure) before increasing the temperature from 26° C. to120° C., where the reaction continued for 16 hours. Then the reactiontemperature was increased to 150° C. and pressure increased to 950 psig(6,550 kPa, gauge pressure), where the reaction continued for anadditional 24 hours. The reactor was then cooled down, depressurized andthe product mixture was discharged and then filtered. The carbonylationproduct mixture was observed to be a dark liquid. The olefin conversionwas measured to be 79% with yield to carbonyl product estimated at 94%by gas chromatography.

Step B2b: Hydrogenation of the Carbonylation Product Mixture

In a 1 gallon (3.78 liter) autoclave, 25.7 grams of Pt/C catalyst wasslurried into the carbonylation product mixture made in step B2a above.The reactor was then purged three times with nitrogen. The reactor wasthen pressured up with 100% H₂ to 500 psig (3447 kPa, gauge pressure)and the temperature increased to 50° C. Afterwards, the temperature wasraised to 100° C. and the pressure was finally increased 2250 psig(15,500 kPa, gauge pressure). The reactor was held under theseconditions for 24 hours and then cooled and depressurized. The catalystslurry was filtered from the liquid mixture by vacuum filtration. Extentof hydrogenation was estimated to be nearly 100%. Gas chromatographyshowed that yield of heavy components (components having a boiling pointhigher than 3-octyltridecan-1-ol) was 0.8 wt %.

Step B2c: Distillation to Obtain an Alcohol Product

A batch distillation was used to remove light components and undesiredheavy components to produce an alcohol product overhead. The alcoholproduct was measured to have a KV100 of 4.35 cSt, a KV40 of 34.2 cSt,and a viscosity index of −60.7, which are slightly different from thoseof the C21-alcohol in Example B1.

Gas chromatography of the alcohol product in this Example B is alsoprovided in FIG. 2, super-imposed to the gas chromatography of theC21-alcohol product from Example B1 above. Clearly the alcohol productfrom this Example B2 comprises multiple compounds having similarstructures and molecular weights. Without intending to be bound by aparticular theory, the alcohol product from this Example B2 may comprise3-octyltridecan-1-ol and multiple isomers thereof.

Portions of ¹³C-NMR spectra of the C21-alcohol product from Example B1and the alcohol product from this Example B2 are super-imposed andprovided in FIG. 3. It is believed that the peaks shown in FIG. 3 arefor carbon atoms connected to —OH groups of the components present inthe samples. Thus, from FIG. 3, it can be seen clearly that multiplealcohol compounds were present in the alcohol product of this ExampleB2, and essentially only one alcohol product was present in theC21-alcohol product of Example B1. In the alcohol product of thisExample B2, 3-octyltridecan-1-ol (the alcohol present in the C21-alcoholproduct of Example B1) is present, but as a minor component.

Therefore, it is clear that in this Example B2 where no phosphinecompound was included in the catalyst system, multiple alcohols wereproduced, and only a small portion thereof is the gamma-branched3-octyltridecan-1-ol. Owing to structural and molecular weightsimilarity between the multiple alcohol species in the alcohol productof this Example B2, separation them to make a high-purity3-octyltridecan-1-ol (such as the C21-alcohol product of Example B1)would be very difficult.

Thus, inclusion of a phosphine compound in the catalyst system in thecarbonylation step of the vinylidene olefin is important for theproduction of a high-purity gamma-branched alcohol.

What is claimed is:
 1. A process for making an alcohol productcomprising a gamma-branched alcohol having a formula (F-I) below:

where each R¹ group, the same or different, is independently a C2 to C28linear or branched alkyl group, the process comprising the followingsteps: (I) providing a vinylidene feed comprising a vinylidene olefinhaving a formula (F-II) below:

where the R¹ groups correspond to the R¹ groups in formula (F-I) above;(II) contacting the vinylidene olefin with carbon monoxide and hydrogenin the presence of a carbonylation catalyst system comprising arhodium-containing compound and a phosphine compound to obtain acarbonylation product mixture; wherein the contacting with thecarbonylation catalyst occurs at a pressure of at least 510 psig, and(III) contacting the carbonylation product mixture with hydrogen in thepresence of a hydrogenation catalyst to produce an alcohol productcomprising the gamma-branched alcohol, wherein: steps (II) and (III)combined have a selectivity of the vinylidene olefin toward thegamma-branched alcohol of at least 97%.
 2. The process of claim 1,wherein the rhodium-containing compound is selected from rhodium oxides,inorganic salts of rhodium, rhodium salts of carboxylic acids, rhodiumcarbonyl compounds, and mixtures thereof.
 3. The process of claim 1,wherein the phosphine compound is selected from triphenyl phosphine,tri-(n-butyl) phosphine; tri-(tert-butyl) phosphine; tri-(n-pentyl)phosphine; tri-(n-hexyl) phosphine; tri(n-heptyl) phosphine;tri-(n-octyl) phosphine; tri(n-nonyl) phosphine; tri-(n-decyl)phosphine; and any mixture of two or more thereof.
 4. The process ofclaim 1, wherein in step (II), the molar ratio of carbon monoxide tohydrogen is 1:1.
 5. The process of claim 1, wherein steps (II) and (III)combined have a selectivity of the vinylidene olefin toward thegamma-branched alcohol of at least 99%.
 6. The process of claim 1,wherein each R¹ group, the same or different, is independently a linearalkyl group.
 7. The process of claim 6, wherein each R¹ group, the sameor different, is independently selected from ethyl, n-propyl, n-butyl,n-hexyl, n-octyl, n-decyl, n-dodecyl, n-tetradecyl, n-hexadecyl,n-octadecyl, n-icosyl, n-docosyl, n-tetracosyl, n-hexacosyl, andn-octacosyl.
 8. The process of claim 6, wherein each R¹ group, the sameor different, is independently selected from ethyl, n-propyl, n-butyl,n-hexyl, n-octyl, n-decyl, and n-dodecyl, n-tetradecyl, n-hexadecyl, andn-octadecyl.
 9. The process of claim 1, wherein the two R¹ groups areidentical.
 10. The process of claim 1, wherein in step (I), thevinylidene feed consists essentially of a single vinylidene olefinhaving a formula (F-II).
 11. The process of claim 1, wherein in step(I), the vinylidene feed comprises multiple vinylidene olefins eachhaving a different formula (F-II).
 12. The process of claim 11, whereinthe multiple vinylidene olefins differ in terms of molecular weightthereof by no more than 150 grams per mole.
 13. The process of claim 1,wherein step (I) comprises the following steps: (Ia) providing a monomerfeed comprising a terminal olefin having a formula (F-III) below:R¹—CH═CH₂  (F-III), where R¹ corresponds to one of the two R¹ groups informula (F-II); (Ib) oligomerizing the monomer feed in anoligomerization reactor in the presence of a catalyst system comprisinga metallocene compound to obtain an oligomerization product mixture; and(Ic) obtaining the vinylidene feed from the oligomerization productmixture.
 14. The process of claim 13, wherein in step (Ia), the monomerfeed comprises a single terminal olefin having a formula (F-III). 15.The process of claim 13, wherein in step (Ia), the monomer feedcomprises multiple terminal olefins having differing formula (F-III).16. The process of claim 15, wherein in step (Ia), the multiple terminalolefins differ in terms of molecular weight thereof by no more than 100grams per mole.
 17. The process of claim 13, wherein: in step (Ib), themetallocene compound has a formula Cp(Bg)_(n)MX₂Cp′, wherein M isselected from Hf and Zr; each X is independently a halogen or ahydrocarbyl group; Cp and Cp′, the same or different, independentlyrepresents a cyclopentadienyl, alkyl-substituted cyclopentadienyl,indenyl, alkyl-substituted indenyl, 4,5,6,7-tetrahydro-2H-indenyl,alkyl-substituted 4,5,6,7-tetrahydro-2H-indenyl, 9H-fluorenyl, andalkyl-substituted 9H-fluorenyl; each Bg is a bridging group covalentlylinking Cp and Cp′; and n is 0, 1, or 2; and the catalyst system furthercomprises an alumoxane.
 18. The process of claim 17, wherein: step (Ib)is carried out in a continuous process at a temperature in the rangefrom 50 to 90° C.; and in step (Ib): the metallocene compound is fedinto the oligomerization reactor at a feeding rate of R(mc) moles perhour, the alumoxane is fed into the oligomerization reactor at a feedingrate of R(Al) moles per hour, the monomer is fed into theoligomerization reactor at a feeding rate of R(to) moles per hour,350≤R(to)/R(mc)≤750, 2≤R(Al)/R(mc)≤10, an oligomer mixture comprisingthe vinylidene olefin and a trimer of the terminal olefin is produced,and the selectivity toward the trimer is less than 5%.
 19. The processof claim 18, wherein in the metallocene compound, M is Zr.
 20. Theprocess of claim 18, wherein X is Cl.
 21. The process of claim 18,wherein the alumoxane is methyl alumoxane.
 22. The process of claim 18,wherein at least one of the following conditions is met:600≤R(to)/R(mc)≤750; and2≤R(Al)/R(mc)≤5.
 23. The process of claim 18, wherein step (Ib) has aconversion of the terminal olefin of no less than 40%.
 24. The processof claim 18, wherein step (Ib) has a selectivity of the terminal olefintoward the vinylidene olefin of at least 95%.
 25. The process of claim24, wherein step (Ic) does not include a step of removing a trimer ofthe terminal olefin from the oligomer mixture.